cool!
thanks for all the info guys. MUCH appreciated
i found 2 or 3 really good videos on you tube about people making iron man and master chief costumes out of pepakura, resin, fiberglass and bondo. definately looks like the sanding/bondo part's going to require alot of patience but it makes me very excited to get to work

now one last quick question (or 2 really)! after applying the bondo and i sand it down and find there's little holes, uneven parts, dips, or rough spots do i just apply more bondo over that spot or do i use that filler stuff?? does the filler hold up like bondo?